Opel Frontera UBS. Service manual — part 2684

7C–20

CLUTCH

2. Adjust clutch padel adjusting bolt by backing it out

half a turn, and measure the clearance (

d

)

between the clutch pedal arm and the adjusting
bolt.

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Legend

(9) Bracket

(10) Clutch Pedal Adjusting Bolt

(11) Lock Nut

(12) Clutch Pedal Arm

3. Lock the lock nut.

Clutch Switch and Clutch Pedal Clearance (

d

)

0.5 mm – 1.5 mm (0.020 in – 0.059 in)

5. After adjusting the clutch pedal height, push the

clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.

Pedal Free Play (4)

5 mm – 15 mm (0.20 in – 0.59 in)

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6. Clutch pedal engagement height inspection:

1. Operate the parking brake lever and block the

wheels.

2. Start the engine, fully step on the clutch pedal,

and move the shift lever to 1st position.

3. With the engine idling, release the clutch pedal

slowly and measure its stroke just prior to its
clutching position.

Clutch Pedal Engagement Height (14)

MIN. 30 mm (1.18 in)

7. If the measured value exceeds the specified limit,

check the following points. Repair if necessary:

D

Hydraulic circuit for fluid leakage or air in circuit.

D

Clutch disc warped.

D

Diaphragm spring weakened or tip of fingers worn.

D

Driven plate sticking on sprines.

D

Release bearing worn or damaged.

D

Master cylinder and slave cylinder worn.

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Legend

(3) Floor Panel

(14) Clutch Pedal Engagement Height

CLUTCH

7C–21

Torque Specifications

D

Master cylinder to dash panel
Torque: 16 N·m (1.6 kg·m/12 lb ft)

D

Clutch pedal to dash panel
Torque: 21 N·m (2.1 kg·m/15 lb ft)

D

Master cylinder push rod to yoke
Torque: 17 N·m (1.7 kg·m/12 lb ft)

D

Clutch pipe to master cylinder
Torque: 20 N·m (2.0 kg·m/14 lb ft)

D

Clutch pipe to flex, hose
Torque:
M 10: 16 N·m (1.6 kg·m/12 lb ft)
M 12: 20 N·m (2.0 kg·m/14 lb ft)

D

Slave cylinder to case
Torque: 43 N·m (4.4 kg·m/32 lb ft)

D

Slave cylinder bleeder screw
Torque: 8 N·m (0.8 kg·m/69 lb in)

D

Flexible hose to slave cylinder
Torque: 20 N·m (2.0 kg·m/14 lb ft)

D

Clutch pipe to damper cylinder
Torque: 12 N·m (1.2 kg·m/104 lb in)

D

Damper cylinder bleeder screw
Torque: 8 N·m (0.8 kg·m/69 lb in)

Bleeding

1. Check the level of clutch fluid in the reservoir and

replenish if necessary.
Bleeding the damper cylinder (except V6 LHD
model).

2. Remove the rubber cap from the bleeder screw and

wipe clean the bleeder screw. Connect a vinyl tube to
the bleeder screw and insert the other end of the vinyl
tube into a transparent container.

3. Pump the clutch pedal repeatedly and hold it

depressed.

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4. Loosen the bleeder screw to release clutch fluid with

air bubbles into the container, then tighten the bleeder
screw immediately.

5. Release the clutch pedal carefully. Repeat the above

operation until air bubbles disappear from the clutch
fluid being pumped out into the container. During the
bleeding operation, keep the clutch fluid reservoir
filled to the specified level. Reinstall the rubber cap.
Bleeding the slave cylinder

6. Repeat step 2 through 5 for bleeding the slave

cylinder.

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Legend

(1) Slave Cylinder
(2) Bleeder Screw
(3) Vinyl Tube

7C–22

CLUTCH

Master Cylinder

Disassembled View

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Legend

(1) Master Cylinder Assembly
(2) Gasket

(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper

CLUTCH

7C–23

Disassembly

(4JX1)

1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.

NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.

Inspection and Repair

Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

1. Push rod set length

RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)

2. Push rod nut torque

17 N·m (1.7 kg·m/12 Ib ft)

3. Damper cylinder torque

47 N·m (4.8 kg·m/35 Ib ft)